Systems and methods using thermal energy storage

ABSTRACT

Systems and methods are provided for bimodal refrigeration, which uses a combination of mechanical refrigeration and phase change material (PCM) cells to provide cooling for one or more units of storage, such as freezers, coolers, storage or display cases, open cases (without doors), closed cases (with doors), rack systems (with compressors located remotely), self-contained refrigeration systems (with embedded compressors), in an optimal and efficient manner. In some embodiments, the systems and methods employ intelligent controls which may monitor and receive input for system conditions, time of day, and other conditions, and turn on/off the mechanical refrigeration as appropriate to provide for efficient and cost-effective use of energy.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Pat. Application No. 63/240,512, “SYSTEMS AND METHODS USING THERMAL ENERGY STORAGE,” filed on Sep. 3, 2021, the entirety of which is incorporated by reference.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

TECHNICAL FIELD

The present invention relates generally to refrigeration systems, and in particular to refrigerated containers or enclosures that employ mechanical refrigeration systems to maintain goods at a desired temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a bimodal refrigeration system, in partial cross-section, according to one embodiment.

FIG. 2 illustrates a bimodal refrigeration system, in partial cross-section, according to another embodiment.

FIG. 3 is a block diagram of a computing device for use with a bimodal refrigeration system, according to some embodiments.

FIG. 4 illustrates a bimodal refrigeration system, according to yet another embodiment.

FIGS. 5A-5D illustrates a bimodal refrigeration system, in partial cross-section, according to still another embodiment.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

This description and the accompanying drawings that illustrate aspects, embodiments, implementations, or applications should not be taken as limiting—the claims define the protected invention. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the spirit and scope of this description and the claims. In some instances, well-known circuits, structures, or techniques have not been shown or described in detail as these are known to one skilled in the art. Like numbers in two or more figures represent the same or similar elements.

In this description, specific details are set forth describing some embodiments consistent with the present disclosure. Numerous specific details are set forth in order to provide a thorough understanding of the embodiments. It will be apparent to one skilled in the art, however, that some embodiments may be practiced without some or all of these specific details. The specific embodiments disclosed herein are meant to be illustrative but not limiting. One skilled in the art may realize other elements that, although not specifically described here, are within the scope and the spirit of this disclosure. In addition, to avoid unnecessary repetition, one or more features shown and described in association with one embodiment may be incorporated into other embodiments unless specifically described otherwise or if the one or more features would make an embodiment non-functional.

Many goods and items, including a substantial portion of the world’s food supply, are preserved using mechanical refrigeration systems to maintain such goods and items at a desired temperature. Given that the per-square-foot cost for refrigeration is higher than any other use of energy, the need for efficiency here is greater than ever.

Various techniques have been developed to provide more efficient refrigeration systems. These include a bimodal refrigeration system and method, as described in U.S. Pat. No. 6,758,057, and a forced air thermal energy storage system, as described in U.S. Pat. Application Pub No. 2017/0321912, both of which are incorporated by reference herein. Such systems and methods employ phase change material (PCM) in conjunction with mechanical refrigeration systems.

According to various embodiments, systems and methods are provided to further improve upon employing PCM (e.g., contained in one or more bottles, cells, or other containers) in conjunction with mechanical refrigeration systems. These include the combination of energy efficiency and operating strategies to reduce greenhouse gases, address climate change, optimize energy usage for “off-peak” hours, combining or modifying operations to coordinate with wind, solar, or other renewable sources of energy generation or energy market dispatch signals, meeting the increasing demand for fresh “real” foods, and resiliency protection against rolling power blackouts and disasters (earthquakes, flooding, fire, hurricanes, terrorist attacks) that may impact the power grid.

The systems and methods can integrate into existing refrigeration or cooling systems of any size, including in larger commercial or industrial warehouse installations, retail installations (e.g., in grocery stores), and residential applications (e.g., home refrigeration and freezer units). This technology includes sensors and controls added to various zones and key points (condensers, doors) of a facility or refrigeration system; monitoring equipment (local and remote) and analytics to process the collected data; control interfaces; communications through Internet of Things (IoT) and cloud-based networks; portal service; remote access from portable devices (e.g., smartphones, notebooks, tablet computers); connection to, and integration with, third-party hardware, apps, and channel partners (third party controls, smart meters, power utilities).

The systems and methods can be employed or used in retail installations, such as grocery and convenience stores. Various issues or problems may arise in refrigeration systems for retail installations. For example, many grocery store refrigeration systems are custom configured for a particular location and may employ a common bank of compressors for multiple refrigeration needs (e.g., reach-in freezers, case coolers, inventory storage, produce, meat, dairy, etc.). This can lead to challenges in controlling temperature across multiple units (each with its own respective target or desired temperature range), controlling over time of energy consumption via TES, and overall energy efficiency. Other issues or considerations for such installations include:

-   Total British Thermal Unit (BTU) required to support the desired     temperature and length of storage. For extended management of energy     consumption (hours). Mitigate door openings (minutes). Thermal     support for product rotation (24 hour loading). -   BTU loading of display lighting, door fog heaters, air curtains,     etc. -   Rate of heat transfer for the products, e.g., packaging and airflow. -   When and how to re-freeze for next cycle of operation. Can re-freeze     be isolated from the product space (temperature swing). -   Space required for PCM. Maintain usable product storage space.     Locations within storage area (shelves, etc). Locations within     ducting or other airflow. As part of the compressor loop/piping     (rather than air).

In retail installations, systems of methods of the present disclosure can be applied, incorporated, employed, or implemented in freezers, coolers, storage or display cases, open cases (without doors), closed cases (with doors), rack systems (with compressors located remotely), self-contained refrigeration systems (with embedded compressors), applications without fan control, etc. The technology of the present disclosure (e.g., control systems, PCM cells) may be deployed and distributed throughout grocery store installations for optimization and increased energy efficiency, for example, to monitor, control, and improve operational visibility on door openings, occupancy, temperatures, equipment, power outages, overall system performance, and other key indicators.

Embodiments of the present disclosure may utilize a bimodal refrigeration system. The bimodal refrigeration system employs an endothermic storage material within a refrigerated container or housing in a manner that leverages the features of conventional mechanical refrigeration units, such as mechanical refrigeration units employing forced-air chilling. In conjunction with the “active” heat exchange mode provided by the forced-air mechanical refrigeration unit, the bimodal refrigeration system employs a “passive” heat exchange mode in the form of an endothermic storage apparatus (e.g., comprising one or more PCM cells) compatibly deployed within the refrigerated container or housing. As used herein, a “bimodal” refrigeration system may refer to a heat extraction/absorption system employing a passive heat exchange mechanism in the form of an endothermic storage material in conjunction with an active heat exchange mechanism in the form of a forced-air mechanical refrigeration system. Furthermore, the bimodal cooling mechanism of the present disclosure reduces the required active operating time and excessive cycling of the mechanical refrigeration system, thereby reducing the overall energy supply requirements and also reducing repair and maintenance costs of the mechanical refrigeration system.

FIG. 1 illustrates an exemplary bimodal system 1000, in partial cross-section, in accordance with some implementations. An application for such system 1000 can be, for example, as a display case or storage in a commercial or retail facility for one or more food, drink, or other items that are preferably kept at a lower temperature.

As shown, the system 1000 comprises a housing formed at least in part by a wall 1002 extending along the top, back, and bottom of the display case or system 1000. The wall 1002 may comprise a layer of foam or other insulating material located or sandwiched between skins of durable material (e.g., metal or plastic) on either side. The wall 1002, at least in part, defines an interior and an exterior for the housing. The interior of the housing is used to hold or store various items or packages (e.g., for food or drink) that are preferably kept at a lower temperature than the ambient surroundings or environment. In some embodiments, the skin adjacent the interior of the housing can be formed of plastic, and the skin adjacent the exterior of the housing can be formed of metal. In other embodiments, both skins are formed of the same material, such as metal. The foam or insulating material in the wall 1002 provides a thermal break to insulate and minimize or reduce thermal exchange between the interior and exterior of the housing.

Supports 1005 and 1007 (e.g., formed of metal) may provide structural support at the rear and bottom of the unit 1000. One or more metal shelves and shelf supports 1011, attached to or proximate the back of the display case or wall 1002, can be used to hold various items or packages (e.g., for food or drink). Users (e.g., customers or employees) of the commercial or retail facility may “reach-in” to system 1000 in order to access, place, or retrieve items to and from the interior of the system housing.

In some examples, the system 1000 comprises one or more doors 1012 which can be opened to access the food or drink items or packages. In a commercial or retail setting, doors 1012 can be formed at least in part of glass or clear plastic to allow a user (e.g., shopper) to see the items stored or kept within the housing interior of system 1000. The wall 1002 (with layer of foam) and door 1012 insulate the interior of system 1000 from the ambient environment or temperature outside the unit. In some examples, system 1000 may not have any doors; that is, it is an open format unit where the interior is open to the ambient environment. In some applications or installations, because cold air from open format units is assumed to “spill” into the surrounding environment, such units are considered or used in conjunction with conventional heating, ventilation, air conditioning (HVAC) systems for overall cooling needs.

In some embodiments, system 1000 may be connected or in fluid communication with a refrigeration system. In some embodiments, the refrigeration system may employ or comprise a common bank of compressors for multiple refrigeration needs (e.g., reach-in coolers and freezers, case coolers, inventory storage, produce, meat, dairy, etc.) in the retail installation. In some embodiments, the refrigeration system operates to cool a liquid refrigerant which is then circulated or supplied through a network of pipes, ducts, valves, pumps, etc. or other fluid communication to system 1000, which may be just one of multiple units that is located throughout a retail or commercial facility and supplied with cooling via the liquid refrigerant. In other embodiments, the refrigeration system may generate chilled air, which is then circulated or moved by a forced air convection system for delivery to system 1000.

In some embodiments, system 1000 includes mechanisms for handling the air (including chilled air) within the unit, including to address convection. These mechanisms can include various blowers, fans, louvers, vents, ducts, etc. for allowing, moving, or distributing air coming into and within unit 1000. As seen in FIG. 1 , system 1000 comprises an air grill 1001, one or more air ducts 1003, 1004 through which chilled air is delivered into the unit 1000. In some embodiments, the chilled air may be produced by circulating air across coils or pipes carrying the cooled liquid refrigerant supplied from the common refrigeration system. In some embodiments, these coils are located in relatively close proximity to system 1000. Air duct 1003 may be located between the top portion of wall 1002 and sheet metal spaced from the wall, and air duct 1004 is located between the back portion of the wall 1002 and sheet metal spaced from the wall skin. System 1000 may include a fan system comprising one or more fan motors and blades 1008 to provide, support, or promote circulation of the chilled air throughout the interior of system 1000. In an open format unit, one or more fans may be used to provide or support an “air curtain” to help isolate the refrigerated space from the ambient environment. The fan system may be implemented or comprise a reversible fan, which can cause the air to flow in different directions throughout the system 1000. For example, arrow 1013 indicates one direction of air flow from the top air grill 1001. A fan plenum 1009 may be formed or defined by bottom foam wall skin and one or more coil covers 1010. In some embodiments, system 1000 comprises an evaporator coil 1006.

According to some embodiments of the present invention, systems and methods implement or utilize the latent energy state of PCM within a refrigeration system to optimize the control and refrigeration system operations. In some embodiments, this is accomplished by the addition of Thermal Energy Storage (TES) capacity in the form of one or more discrete, sealed cells, packets, bottles, or containers of PCM to the system 1000. As shown in FIG. 1 , these PCM cells 1101, 1102, 1103, 1104, 1105, 1106, 1107, 1108, 1109, and 1110 can be distributed or integrated throughout the unit 1000. PCM cell 1101 is integrated into the structure of the top air duct. PCM cell 1102 is mounted in top air duct. Cells 1103 are formed into a module that rests on a shelf. PCM cell 1104 is located in rear air duct. PCM cells 1105 are integrated into the structure of the rear air duct. PCM cells 1106 are integrated into the structure of the evaporator coil. PCM cells 1107 are located in the fan plenum. PCM cells 1108 are integrated into the structure of the fan and coil cover. PCM cells 1109 are secured to the bottom of the shelving. PCM cells 1110 are integrated into the structure of the shelving.

In some examples, one or more PCM cells 1101-1110 may comprise a bottle or container made of, for example, high density polyethylene plastic. The shape of the PCM cell may be, for example, cylindrical, rectangular, in the form of a panel, or any other suitable shape. Likewise, the PCM cells can be configured in any suitable size. In some examples, the PCM cells 1101-1110 used with unit 1000 may be configured with multiple or different shapes and sizes, as or appropriate for placement and distribution in different areas in reach-in unit 1000.

The PCM cells 1101-1110 can include or contain thermally chargeable material. In some embodiments, the thermally chargeable material can comprise an endothermic storage material, which in some examples, can change phase (e.g., from solid to liquid, and vice versa) as the material absorbs heat, thereby reducing the surrounding temperature. In some embodiments, the quantity and/or type of phase change material (PCM) may be set based on a desired temperature range at which the goods or items contained in the unit are to be maintained. The PCM cells 1101-1110 may be brought to stasis by maintaining the PCM material at a specified stasis temperature for sufficient period, typically several hours. Once activated or charged, the PCM material within PCM cells 1101-1110 remains active (i.e. in a phase change or stasis condition) for an extended period of time. As ambient heat infiltrates the interior housing of the system 1000, this heat is selectively absorbed by the PCM material rather than the goods, such that the temperature of the goods and the interior housing of system 1000 remains below a predetermined maximum temperature for longer period than if the PCM cells 1101-1110 were not present. PCM cells 1101-1110 are brought to stasis by the chilled air derived from the chilled delivery medium (e.g., cooled liquid refrigerant) from the refrigeration system, as circulated or distributed by the fans, louvers, vents, ducts, etc. of system 1000. This insures that PCM cells 1101-1110 reach stasis within the shortest possible time.

The PCM can be specially configured with a formulation that provides properties for phase change or stasis temperature that are suitable or appropriate for the products or items to be kept cold. For example, water/ice may not be the ideal PCM eutectic for many applications, as the temperature at which it solidifies or melts is 32° F. (0° C.). Most freezers normally run at 0° F. and most refrigerators normally run above 32° F. Thus, according to some embodiments, the PCM eutectic is matched to the operating system or compartment and the kinds of goods to be contained therein. In other words, the phase change material may be formulated or configured with a solid-liquid phase temperature based on a desired temperature profile or range of the unit 1000. In one or more embodiments, the phase change material may be a combination of water and one or more salts, where the quantity of the salts is selected, at least in part, on a desired temperature profile—i.e., so that the solid-liquid phase change transition temperature is set somewhere between the maximum and minimum ends of the desired temperature range. In some embodiments, different PCM formulations may be used for different compartments, regions, locations, or zones in the same system 1000, for example, if the target temperature profile for some items is different from other items. For example, some frozen meat and ice cream products are preferably kept chilled at temperatures different from those for other frozen foods. Likewise, some varieties of white wine are preferably kept chilled at lower temperatures than some varieties of red wine. Different formulations of PCM are selected and placed in the different zones for white and red wines as appropriate for the preferred temperature profiles.

In operation for reach-in system 1000, the convective airflow, for example, supported by fan system of the system 1000, causes air to pass by the PCM cells 1101-1110, thereby exchanging heat with the PCM cells. This heat exchange causes PCM cells to undergo eutectic change—changing from liquid phase to solid phase, or vice versa. When the refrigeration system is active, and chilled delivery medium (e.g., cooled liquid refrigerant) is provided or circulated to the unit 1000, some of the PCM within the cells may change from liquid phase to solid phase, thus charging the PCM cells as Thermal Energy Storage (TES). When the refrigeration system is not active, or the chilled refrigerant is not being provided or circulated to the unit 1000, some of the PCM with the cells may undergo eutectic change in the other direction, changing from solid phase to liquid phase, thereby discharging the TES and absorbing heat to regulate or maintain the temperature within the unit 1000 at a desired temperature range.

FIG. 2 illustrates an exemplary bimodal system 2000, in partial cross-section, in accordance with some implementations. An application for such system 2000 unit can be, for example, as a single deck freezer display case or storage in a commercial or retail facility for one or more food items.

As shown, the system 2000 comprises a housing, defined or formed in party by a wall 2002 extending along the left, bottom, and right sides of the unit 2000. The wall 2002 may comprise a layer of foam or other insulating material located or sandwiched between skins on either side. The layer of foam acts as an insulator. The skins can be made of metal, plastic, or any other suitable material. The wall 2002, at least in part, can defines an interior and an exterior for the housing of the system 2000. In some examples, freezer system 2000 is an open format system—i.e., the unit does not include a door or lid to close off the unit, and as such, the interior of the system is open to the ambient environment.

In some embodiments, system 2000 may be connected or in fluid communication with a refrigeration system which generates and delivers or circulates cooled liquid refrigerant via ductwork, pipes, valves, pumps, etc., as described above. System 2000 comprises an air grill 2001, one or more air ducts 2003, 2004 through which chilled air (e.g., which is chilled by the cooled liquid refrigerant) is delivered into the unit 2000. A fan system (e.g., reversible) comprising one or more fan motors and blades 2008 to provide, support, or promote circulation of the chilled air throughout the interior of system 2000. A fan plenum 2009 may be formed or defined by bottom foam wall skin and one or more coil covers 2010. In some embodiments, system 2000 comprises an evaporator coil 2006. With an open format, such as system 2000, these mechanisms—e.g., fans, ducts, louvres, etc.—can be configured to handle air flow 2013 and convection to provide or support an “air curtain” between the interior of the system 2000 and the ambient environment.

According to some embodiments, freezer system 2000 may comprise one or more PCM modules, bottles, or cells 2101, 2102, 2103, 2104, 2105, 2106, and 2107, which can be distributed or integrated throughout the system 2000. PCM cell 2101 is mounted in right air duct. PCM cells 2102 are integrated into the structure of the evaporator coil. PCM cells 2103 are located in the fan plenum. PCM cell 2104 is mounted in left air duct. PCM cells 2105 are integrated into the structure of the left air duct. PCM cells 2106 are integrated into the structure of the fan and coil cover. PCM cells 2107 integrated into the structure of the left air duct. PCM cells 2101-2107 provide TES capacity, e.g., to optimize operations for system 2000 and the rest of the systems and infrastructure with which it cooperates. System 2000 operates similarly to system 1000, as described above. PCM cells 2101-2107 can include or contain thermally chargeable material that is specially configured with a formulation appropriate for system 2000, as already described above.

According to some embodiments, each of the reach-in system 1000 of FIG. 1 and the freezer system 2000 of FIG. 2 may also comprise one or more sensors to take measurements or monitor various operating conditions, both within and external to the units. In some examples, these operation conditions can include the temperature at one or more zones of the interior space, temperature of products (e.g., food or drink items), ambient temperature of the environment (e.g., host room) where the unit 1000 or 2000 is located (including potentially heat impact of the room temperature), PCM temperature (e.g., freeze status), coil temperature (e.g., is refrigeration working), door status (openings and length of time), airflow speeds, product loading and incoming temperatures, Time Of Use (TOU) electric utility tariff for optimizing consumption time/costs, metrics related to other utility incentive programs (shed schedules or dispatch signals), Green House Gas (GHG) metrics for the electrical service to optimize consumption GHG impacts (e.g., California local note GHG API system). Such sensors can be implemented as thermometers, motion sensors, proximity sensors, or any other suitable device.

In some embodiments, information or data regarding the measurements taken by the various sensors and monitors may be collected and/or provided, for example, through wired or wireless communication (e.g., WiFi, Bluetooth, cellular) to one or more controllers. The controllers may be configured to control the generation or cooling of the liquid refrigerant by the refrigeration system, and the operation of the system or network of pipes, ducts, valves, pumps, etc. for circulating or delivering the cooled liquid refrigerant to the systems 1000 and 2000, the direction of fan or air circulation systems within systems 1000 and 2000 to regulate their temperature, as well as the temperature of any other units throughout the same retail facility. The controllers may, for example, turn on/off one or more compressors in the refrigeration bank, set, increase, or decrease the temperature within the units (or various zones therein), e.g., according to a predetermined or flexible schedule, independently control airflow fans in the units and/or the liquid refrigerant circulation or delivery system, etc.

FIG. 4 illustrates a system 4000 comprising a plurality of cooling units, a refrigeration system, a liquid refrigerant circulation system, and a control system 4040.

In some embodiments, each of the plurality of cooling units may comprise a reach-in system 1000, a freezer system 2000, or other similar system which holds and makes available items (e.g., food, drink, etc.) that are preferably kept at a lower temperature. As shown in FIG. 4 , system 4000 includes four cooling units which are reach-in systems 1000 (with doors 1012), and another three cooling units which may be freezer systems 2000.

The refrigeration system may comprise a mechanical refrigeration system that operates to generate or cool a delivery medium, such as liquid refrigerant. As shown, in FIG. 4 , the refrigeration system may comprise a condenser fan 4001, a condenser coil 4002, and a bank of compressors 4003.

The liquid refrigerant circulation system operates to deliver and circulate the cooled liquid refrigerant from the refrigeration system to the cooling units of system 4000. A shown, the liquid refrigerant circulation system comprises a suction line 4010, discharge line 4011, liquid line 4012, and liquid receiver or tank 4013.

Control system 4040 provides or supports intelligent control of the system 4000, both in the aggregate and for the individual components. Control system 4040 may receive input signal from, for example, one or more temperature sensors 4041 that are located throughout the system 4000. In some embodiments, at least one temperature sensor 4041 is provided in each cooling unit (system 1000 or system 2000). Control system 4040 may control the turning on/off of the refrigeration system. Control system 4040 may control the circulation of cooled liquid refrigerant, e.g., via a liquid line solenoid valve 4042. According to some embodiments, control system 4040 may provide or support intelligent controls (e.g., algorithms) for optimizing use of PCM in a bimodal system for thermal energy storage (TES), e.g., as implemented in any of system 1000, system 2000, and system 4000.

These algorithms for intelligent controls analyze or take into account multiple factors or variables, including the number and kinds of cooling units (e.g., systems 1000, 2000, and the like) in the system 4000, and for each such unit, the charge/discharge cycle of the PCM, cooling load, type of good or product (e.g., fresh food, frozen food, pharmaceutical, or bioscience material), overall roundtrip efficiency, variable utility rates, integration with wind, solar, or any other renewable power source or market dispatch signal, total energy consumption (kW and kWh) and grid / societal impact, energy costs combining Time Of Use (TOU) and other factors, real-time accommodations for variables (doors, product loading, etc.), space versus product temperature simulations and modeling, unique defrost sequences, and future aggregate dispatch requests or operating signals. Intelligent controls can be implemented at least in part as Software as a Service (SaaS).

Other considerations or factors of intelligent control by control system 4040 can include the following.

Comprehensive consideration both in-front of and behind the power meter. Conventional techniques for cooling system optimization typically stand on one side or the other of the power meter. That is, they attempt to increase efficiency of the installation “behind the meter” by reducing overall power consumption; or alternatively, they attempt to optimize based on considerations “in front” of the meter, e.g., for variable utility rates. Often, the latter creates the wrong incentives, as operators may be driven to consume more overall power just to take advantage of “off-peak” rates in addition to new counter-intuitive utility operating constraints such as Local Node Pricing (LNP). In contrast, systems and methods of the present disclosure, e.g., as implemented with control system 4040, consider or analyze what is happening on both sides of the power meter and can manage competing objectives when controlling for optimization, delivering higher efficiency and reduced overall power consumption, at lower costs. Inclusion of TES as an offset capacity (against compressor operations) for any utility program and dispatchability as an addressable load control device can be used for utility dispatch or load aggregators now able to leverage behind-the-meter systems within the wholesale and other dispatchable front-of-the-meter energy markets.

Reporting and Recommendations. With all of the information and data collected and stored by the control and monitoring systems, the systems and methods of the present disclosure, e.g., as implemented with control system 4040, generate various notices and reports for their users or operators, including how much energy was reduced and energy costs saved through the use of the technology at individual installations or in the aggregate, and how long an installation may be operated without turning on the mechanical refrigeration system while still maintaining the quality of the cooled products or goods. Furthermore, the systems and methods are able to make recommendations to its customers, such as, for example, adding or relocating PCM bottles or containers and/or products, changing refrigeration capacity and equipment operating sequences, instituting building improvements to reduce heat infiltration, migration to new equipment such as Variable Frequency Drives (VFDs), and other business improvements, etc. to further increase efficiency, and reduce costs.

Cloud-based approach. Systems and methods may be implemented or incorporate a cloud-based approach, where information, data may be uploaded to a site remote from the location of the installation, stored, and processed. An advantage of the cloud-based approach is that the systems and methods are able to leverage the information and data collected for some installations, users, or operators (e.g., for energy usage, temperature changes, warehouse practices) to make recommendations and suggestions to other installations, users, or operators. In some embodiments, the systems and methods can apply analytics across the broader set of all installation, user, and operator data (anonymized if necessary for privacy concerns) to increase efficiency, develop best practices suggestions, working with not only private entities but with utilities and governments (e.g., State of California) as well to develop solutions and address issues that are much bigger and more comprehensive that a single site. Additionally, cloud computing facilitates the deployment of artificial intelligence and machine learning.

Installation format. This includes the physical array spacing and installation configurations for PCM bottles or containers as a small heat-exchanger or energy storage (attached to roof, racks, shelves, either separate from or interspersed among items to be kept cold) which is able to use convective airflow (does not require a supplemental fan for air movement) to optimize efficiency. Present configurations include a laydown module, universal module, wire deck module, movable wire basket(s), telescoping module(s), floor option, and associated installations for the same. The configurations provide flexibility to install within unused space in the freezer (not consuming space for product storage) and can be modular, allowing more PCM bottles to be added when and where needed in order to handle increased cooling demands (e.g., more items or lower temperatures).

Control system 4040 can be implemented with the one or more controllers. In some embodiments, the controllers can be implemented as one or more computing devices. FIG. 3 illustrates an embodiment of a computing device 3000 which may be used in the systems and methods of the present disclosure, including in conjunction with reach-in system 1000 of FIG. 1 , the freezer system 2000 of FIG. 2 , and the network system 4000 of FIG. 4 .

The computing device 3000 includes one or more computer processors 3010 coupled to computer storage (memory) 3020, and communication equipment 3030 (e.g., for radio communications).

Operation of computing device 3000 is controlled by processor 3010, which may be implemented as one or more central processing units, multi-core processors, microprocessors, microcontrollers, digital signal processors, field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), graphics processing units (GPUs), tensor processing units (TPUs), and/or the like in computing device 3000.

Memory 3020 may be used to store software executed by computing device 3000 and/or one or more data structures used during the operation of computing device 3000. Memory 3020 may include one or more types of machine-readable media. Some common forms of machine-readable media may include a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, RAM, PROM, EPROM, EEPROM, FLASH-EPROM, any other memory chip or cartridge, and/or any other medium from which a processor or computer is adapted to read.

Processor 310 and/or memory 3020 may be arranged in any suitable physical arrangement. In some embodiments, processor 3010 and/or memory 3020 may be implemented on the same board, in the same package (e.g., system-in-package), on the same chip (e.g., system-on-chip), and/or the like. In some embodiments, computer system 3000 may be located on-site at the retail installation where unit 1000 or unit 2000 are located. In some embodiments, processor 3010 and/or memory 3020 may include distributed, virtualized, and/or containerized computing resources. Consistent with such embodiments, processor 3010 and/or memory 3020 may be located in one or more data centers and/or cloud computing facilities. In some examples, memory 3020 may include non-transitory, tangible, machine-readable media that include executable code that when run by one or more processors (e.g., processor 3010) may cause the computing device 3000, alone or in conjunction with other computing devices in the environment, to perform any of the methods described further herein

The computing device or equipment 3000 may include one or more user input devices 3040, such as a keyboard, a mouse, trackball, touch pad, touch screen, pen or the like, for interacting with a graphical user interface (GUI) provided by the browser on a display (e.g., a monitor screen, LCD display, etc.) of the computing device 3000 in conjunction with pages, forms, applications and other information provided by device 3000 or other systems or servers. For example, the user interface device can be used to access data and applications hosted by system 3000, and to perform searches on stored data, and otherwise allow a user to interact with various GUI pages that may be presented to a user.

Communication equipment 3030 of computing device 3000 may comprise or be implemented with, for example, one or more radios, chips, antennas, etc. for allowing the device 3000 to send and receive signals for conveying information or data to and from other devices. Under the control of processor 310, wireless communication equipment 3030 may provide or support communication over Bluetooth, Wi-Fi (e.g., IEEE 802.11p), and/or cellular networks with 3G, 4G, or 5G support.

In some embodiments, one or more computing devices or equipment are connected or configured in a network. The network can be any network or combination of networks of devices that communicate with one another. For example, the network can be any one or any combination of a LAN (local area network), WAN (wide area network), telephone network, wireless network, point-to-point network, star network, token ring network, hub network, or other appropriate configuration. The network can include a TCP/IP (Transfer Control Protocol and Internet Protocol) network. Some implementations are suitable for use with the Internet, although other networks can be used instead of or in addition to the Internet, such as an intranet, an extranet, a virtual private network (VPN), a non-TCP/IP based network, or the like.

Each computing device 3000 or groups of computing devices 3000 may comprise or incorporate suitable network interfaces. Such network interface provides or supports communications, signaling, etc. between and among the computers of the network, as well as with other systems. In some examples, network interface can comprise or be implemented using one or more HTTP servers. In some embodiments, the network interface provides or includes load sharing functionality, such as load balancing and distribute incoming HTTP requests over a plurality of servers in the system.

In some examples, the various systems and methods described herein (including the use of PCM, sensors, controllers, etc.) can be incorporated or applied in home or residential refrigerator and/or freezer appliances.

FIGS. 5A-5D illustrates an exemplary bimodal system 5000, in partial cross-section, according to still another embodiment of the present disclosure. An application for such system 5000 unit can be, for example, as a consumer appliance in a residential home for providing refrigeration and freezer storage of one or more food, drink, or other items that are preferably kept at a lower temperature.

FIG. 5A is a front view of system 5000. As shown in FIG. 5A, the system 5000 may comprise a housing, the interior of which is accessible through multiple doors 5012, 5014.

FIG. 5B is a cross-sectional view of system 5000 taken along the line marked 5B in FIG. 5A. Referring to FIG. 5B, system 5000 comprises a housing formed at least in part by a wall 5002 extending along the top, back, and bottom of the system 5000. The wall 5002 may comprise a layer of foam or other insulating material located or sandwiched between skins of durable material (e.g., metal or plastic) on either side. The wall 5002, at least in part, defines an interior and an exterior for the housing. Construction of the wall 5002 can be similar to that of the walls 1002 and 2002 as described for systems 1000 and 2000 shown in FIGS. 1 and 2 .

The interior of the housing of system 5000 may be divided by an inner wall or partition into two sections—a refrigeration section 5006, and a freezer section 5008. The refrigeration section 5006 can be used to hold or store various items or packages (e.g., for food, drink, pharmaceuticals) that are preferably kept at a lower temperature than the ambient surroundings or environment but above the freezing point of water (e.g., such as between 32 to 55° F. for fruit, vegetables, beer, dairy products, and the like). The freezer section 5008 can be used to hold or store various items or packages that are preferably kept at a temperature below the freezing point of water (e.g., such as between minus 20 and 32° F. for frozen meat, ice cream, and the like). Each of refrigeration section 5006 and freezer section 5008 may be further divided with shelves, trays, containers, etc. to facilitate and organize the storage of the items kept therein.

Doors 5012 and 5014 (as shown in FIG. 5A) work in conjunction with wall 5002 to insulate the interior of system 5000 from the ambient environment or temperature outside the unit. Like wall 5002, the doors 5012, 5014 can be formed of an insulating material (e.g., foam) disposed between skins formed of a durable, rigid material (e.g., metal or plastic). Doors 5012 and 5014 can be can be opened to access the items or packages stored in the respective sections 5006 and 5008.

Still referring to FIG. 5B, system 5000 further comprises a mechanical refrigeration unit 5010, which is thermostatically controlled to regulate the temperature and provide cooling within the refrigeration section 5006 and freezer section 5008. In some embodiments, the mechanical refrigeration unit 5010 employs a conventional evaporator/condenser system that produces chilled air. Blowers, fans, vents, and ducts (not shown) can be provided in system 5000 to discharge, distribute, and circulate the chilled air into refrigeration section 5006 and freezer section 5008 to achieve rapid temperature control or recovery.

FIG. 5C is a side view of system 5000, and FIG. 5D is a cross-sectional view of system 5000 taken along the line marked 5D in FIG. 5C. FIG. 5D shows that in some embodiments, the refrigeration or freezer section 5006 or 5008 can be further divided or defined by additional interior walls or partitions in system 5000.

System 5000 further includes one or more PCM cells 5016, which can be distributed or integrated throughout the interior and walls of system 5000. The PCM cells 5016 may comprise a container or bottle, formed in any suitable shape and size, which contains thermally chargeable material, as already described herein with reference to other embodiments. In some embodiments, the PCM cells 5016 are removable so that they can be changed out, e.g., with different formulations of PCM, to adjust for the items stored therein.

In some embodiments, at least some PCM cells 5016 may be located or contained in inner wall or partition which separates refrigeration section 5006 and a freezer section 5008. With this arrangement, PCM cells 5016 can help to regulate the temperatures in section 5006 and 5008, for example, by providing or facilitating thermal transfer between the two sections.

PCM cells 5016 work in conjunction with mechanical refrigeration unit 5010 to provide for more efficient and cost-effective cooling for system 5000. In particular, mechanical refrigeration unit 5010 can be controlled to be turned on during “off-peak” hours of energy consumption (e.g., early in the morning), when rates are lower, to charge PCM cells 5016 (e.g., by changing from liquid to solid, and releasing thermal energy). Then, as the system 5000 is operating during “peak” hours of energy consumption (e.g., late afternoon and early evening), when rates are higher, the PCM cells can provide cooling for system 5000 (e.g., by changing from solid to liquid, and absorbing thermal energy) so that the mechanical refrigeration unit 5010 can be turned on less frequently, thereby reducing costs of operation, as well as lessening the impact on the power grid.

System 5000 can include or be controlled by intelligent controls, for example, as implemented with the computing device 3000 of FIG. 3 , to monitor and receive input for system conditions, time of day, and other conditions, and turn on/off the mechanical refrigeration unit 5010 as appropriate to provide for efficient use of energy. For example, in some embodiments, the intelligent controls can be provided with input for energy that may be generated by a solar panel installation at the residence where system 5000 is located. The intelligent controls may be programmed or configured to divert or send any “extra” power generated by the solar panel installation (that would not otherwise be used within the household or residence) to the system 5000 to turn on mechanical refrigeration unit 5010, thereby recharging the PCM cells, even during “peak” hours. From the perspective of the homeowner or resident, such use of the extra power from the solar installation is more desirable than letting the power go to waste or selling the extra power to the energy company, which typically pays less for the energy than it buys as compared to what the company charges.

This description and the accompanying drawings that illustrate inventive aspects, embodiments, implementations, or applications should not be taken as limiting. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the spirit and scope of this description and the claims. In some instances, well-known circuits, structures, or techniques have not been shown or described in detail in order not to obscure the embodiments of this disclosure. Like numbers in two or more figures typically represent the same or similar elements.

In this description, specific details are set forth describing some embodiments consistent with the present disclosure. Numerous specific details are set forth in order to provide a thorough understanding of the embodiments. It will be apparent, however, to one skilled in the art that some embodiments may be practiced without some or all of these specific details. The specific embodiments disclosed herein are meant to be illustrative but not limiting. One skilled in the art may realize other elements that, although not specifically described here, are within the scope and the spirit of this disclosure. In addition, to avoid unnecessary repetition, one or more features shown and described in association with one embodiment may be incorporated into other embodiments unless specifically described otherwise or if the one or more features would make an embodiment non-functional.

Although illustrative embodiments have been shown and described, a wide range of modification, change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the embodiments may be employed without a corresponding use of other features. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. Thus, the scope of the invention should be limited only by the following claims, and it is appropriate that the claims be construed broadly and in a manner consistent with the scope of the embodiments disclosed herein. 

What is claimed is:
 1. A reach-in system with bi-modal refrigeration, comprising: a housing comprising one more walls defining an interior space, wherein the interior space is capable of holding one or more items desirably maintained at a target temperature range, wherein a human user can retrieve such items from the interior space of the housing by reaching in; means for fluid communication between the interior space and a chilled air generation system, wherein the fluid communication means is capable of delivering chilled air from the chilled air generation system to the interior of the housing; and one or more cells of phase change material (PCM) located within the housing, wherein the cells of PCM are capable of working in conjunction with the fluid communication means delivering chilled air from to chilled air generation system to maintain the interior of the housing at the target temperature range.
 2. A bimodal refrigeration system comprising: a plurality of cooling units, wherein each cooling unit comprises a housing defining an interior operable to store one or more goods and a plurality of phase change material (PCM) cells disposed throughout the housing interior; a refrigeration system common to the plurality of cooling units and operable to generate a chilled medium for cooling the cooling units; a circulation system for circulating the chilled medium between the plurality of cooling units and the refrigeration system; one or more sensors operable to sense conditions at each of the plurality of cooling units; and a control system operable to receive input from the one or more sensors, and based on such input, control the refrigeration system and the circulation system to generate and direct the chilled medium to the plurality of cooling units to provide cooling and charge the PCM cells, wherein the PCM cells operable to provide cooling for the respective cooling unit when chilled medium is not being provided. 